---
title: "Barudan Embroidery Machine Troubleshooting: Error Codes, Thread Breaks and Fixes"
description: "Barudan A- and D-series error codes explained, plus fixes for thread breaks, birdnests, trimmer and colour change errors, hook timing and oiling."
url: https://easydigitizer.com/troubleshooter/barudan
updated: 2026-10-14
brand: Barudan
class: commercial
origin: Japan
formats: Barudan FDR (.U01, .U02 …), DSB, DST (Tajima) on USB, CF card, floppy (older) or B-NET/DFS network
data: https://easydigitizer.com/troubleshooter/data.json
agent_playbook: https://easydigitizer.com/troubleshooter/agent.md
publisher: EasyDigitizer (https://easydigitizer.com/)
---

# Barudan embroidery machine troubleshooting

Barudan A- and D-series error codes explained, plus fixes for thread breaks, birdnests, trimmer and colour change errors, hook timing and oiling.

> **Short answer:** Most Barudan stops come down to three things: threading and tension (check the thread is wrapped round the thread-break wheel, then run an 18 mm capital "I" test), a dirty or dry hook (one small drop of oil in the raceway every 4–8 hours of sewing), and lint or thread wrapped behind the hook. The codes you will see most often are **D25 Stopped for Thread Break**, **D12 Trimmer Slider Error** and **D05 Colour Change Error**. Barudan's own FAQ says hook timing is one of the *last* things to check for skipped stitches.

## Model families
### Pro3 / BEKT-S1501CBIII (KT single-head)
- **Type:** Commercial single-head, bridge-style chassis, 15 needles
- **Years:** current
- **Field:** about 360–380 × 500 mm (Barudan's page lists both figures)
- **Max speed:** not stated on the product page
- **Panel:** KT Automat, 8.4 in colour touch screen, 100 designs / 70 million stitches
- **Formats:** USB stick, B-NET LAN, bar-code scanner ready
- **Manual:** [Pro3 maintenance manual (PDF)](https://www.barudanamerica.com/wp-content/uploads/2019/09/CB%E2%85%A2-Maintenance-manual-InstallationService_190304R00E_R3.pdf)
- **Tags:** single-head, cap, 15-needle, touch screen, SH head
The current flagship single head, built on the quiet SH sewing head with positive needle drive, the MK8 trimmer and the newer tensioner. Shows the same A/D message family as the KS/KY/KT/XS/XY/XT line. Typical trouble: thread not wrapped round the detect wheel (false D25), trimmer slider catching untrimmed thread (D12), and needle-bar/colour-change binds after a hoop strike.

### XL2 / BEKT-S1501CAII (KT single-head)
- **Type:** Commercial single-head, 15 needles
- **Years:** current
- **Field:** 250 × 400 mm
- **Max speed:** 1,200 spm flats, 1,000 spm caps
- **Panel:** KT Automat with touch screen
- **Formats:** USB stick, LAN for Barudan networking software
- **Manual:** [CAII/CBII/CBIII lubrication guide (PDF)](https://www.barudanamerica.com/wp-content/uploads/2019/06/CAII_lubrication_r6.pdf)
- **Tags:** single-head, cap, 15-needle, compact
The smaller-field KT single head, often used for caps and left-chest work. Same oiling chart as the CBII/CBIII heads. Cap work at full flat speed is a common cause of flagging and thread breaks; keep caps at or below 1,000 spm.

### C01 / BEXT and BEVT-S1501CII (single-head bridge)
- **Type:** Commercial single-head bridge machine, 15 needles
- **Years:** previous generation
- **Panel:** X/V-series Automat
- **Formats:** USB or CF card depending on build, DST and Barudan formats
- **Manual:** [BEXT/BEVT-S1501CII lubrication guide (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/Tech-lubricationLubrication-Inst-for-BEVT-S1501CII_20130613R02.pdf)
- **Tags:** single-head, bridge, 15-needle, S head
A single head built like one position of a multi-head. Uses the X/V error lists. Bridge heads time the hook at 25° on the degree wheel (arm heads use 23°).

### LY / KY compact multi-heads (BELY, BEKY, BEXY-S15xxCII)
- **Type:** Commercial multi-head, 2–8 heads, 15 needles
- **Years:** current (KY/XY versions earlier)
- **Field:** 450 × 520 mm or 450 × 380 mm per head
- **Max speed:** 1,100 spm flats, 1,000 spm caps
- **Panel:** 10.4 in colour touch screen
- **Formats:** USB stick (up to 5,000 designs in 50 folders), LAN for B-NET
- **Manual:** [Multi-head compact lubrication guide (PDF)](https://www.barudanamerica.com/wp-content/uploads/2019/05/Tech-lubricationLubrication-Inst-for-S15XXC2_20130613R04.pdf)
- **Tags:** multi-head, cap, 15-needle, tubular
The workhorse compact multi-head. Head-specific problems (one head breaking thread, one head birdnesting) are almost always that head's threading, needle, hook or bobbin case. D30 appears if more than one head switch is set wrong on a head/duct board.

### XS / XY and VS / VY multi-heads (BEXS, BEXY, BEVS, BEVY)
- **Type:** Commercial multi-head, flat (S) and tubular (Y) tables
- **Years:** about 2000s–2010s
- **Panel:** Automat with graphic LCD
- **Formats:** CF card (V series), USB (X series), floppy on early V machines, DFS/LEM network
- **Manual:** [VS/VY error messages (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/VS-VY_Error_Messages.pdf)
- **Tags:** multi-head, cap, 9-needle, 15-needle, YN head
Large-production machines with YN (9-needle) or ZQ/S heads. V-series limits a design to 400 colour changes; K/X-series allows 1,200. Early V machines still read floppy disks, so A30–A33 messages show up when a disk is unformatted, write-protected or mixes file types.

### Elite Pro and Elite Pro II (BEVT-Z1501CB / CBII, BEDT-ZQ-501)
- **Type:** Commercial single-head, 15 needles, ZQ bridge-style sewing head
- **Years:** about 2003–2010s
- **Panel:** VT Automat
- **Formats:** CF card, DST and Barudan formats
- **Manual:** [Elite Pro II and Pro oiling guide (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/EliteProIILubrication.pdf)
- **Tags:** single-head, cap, 15-needle, ZQ head
Very common in small shops. If the Automat shows "N00" the colour change is stuck between needles; Barudan's VT error sheet describes resetting it with a 4 mm Allen key on the manual colour-change shaft behind the tension base. Take-up levers out of line at "TOP" mean the head was knocked out of sync, usually by a hoop strike.

### Elite XL, Elite Jr and Elite XLII (BEVT-Z901CA, BEDT-ZN-101, BEVT-S901CAII)
- **Type:** Commercial single-head, 9 needles
- **Years:** about 2002–2010s
- **Panel:** VT Automat
- **Formats:** CF card, DST and Barudan formats
- **Manual:** [Elite XLII maintenance manual (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/CAII_Maintenance_Manual-revised5.pdf)
- **Tags:** single-head, cap, 9-needle, ZN head
Nine-needle machines with three top tensioners per needle (upper, centre and lower/rotary). The lower rotary wheel must keep turning while sewing; if it stalls, back off the lower and add tension on the upper.

### D, N and M series (BEDT/BEDS/BEDY, BENS/BENY/BENR/BENT, BEMR/BEMS)
- **Type:** Commercial single and multi-head, ZQ (15), ZN (9), YN (9) or YS (7) heads
- **Years:** M series about 1989–1995, N series about 1995–2001, D series 2001 on
- **Panel:** N/D series monochrome or colour graphic LCD Automat; M series LED or text LCD
- **Formats:** floppy disk (FDR or DOS), serial (U code), later network
- **Manual:** [ZQ/ZN hook timing guide (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/KBHookTiming.pdf)
- **Tags:** multi-head, single-head, legacy, floppy
Older machines still running in many shops. Barudan's model decoder explains the name: BE + series letter + model letter + table type + head type + heads (for example BEDYHE-ZQ-C04). D-series machines have the under-thread sensor and trimmers as standard. Common issues are worn check springs (missed thread breaks), floppy drives, and serial transfer settings.

### BEAT series (BEAT-10X to BEAT-90X, BEAT-IV)
- **Type:** Commercial single and multi-head with built-in lettering keyboard
- **Years:** about 1981–1997
- **Panel:** LCD, vacuum fluorescent display, or PC-based with monitor (BEAT-90X)
- **Formats:** floppy, Barudan formats
- **Tags:** legacy, lettering, monogram
Legacy machines. The BEAT-900 can show "Unexpected Fatal Error"; Barudan's FAQ says a System Reset from the boot shell menu usually clears it.

## Error codes
| Code | Message | Meaning | Fix | Models | Source |
|---|---|---|---|---|---|
| A01 | No or Low Battery Voltage | The memory backup battery on the CPU board is flat, usually after a long power-off or a new CPU board | Leave the machine switched on for 24 hours to recharge. If it will not hold charge, call Barudan for a battery | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A05 | Wrong Tape Code or BAUD Rate Error | A serial (COM) transfer arrived in a code or speed the machine is not set for | Match the PC's output code to the machine's IN COM setting (Barudan = U, Tajima = EL, ZSK = F) and match the baud rate on both ends | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A07 | IC Memory Error | Writing to the control board's memory chip failed | Control board fault. Call Barudan tech support | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A08 | Memory is Full or Design Memory Read Error | No room for the design, or the design could not be read in | Delete designs. Rename the problem file or try a known-good design. If nothing loads, the internal CF card may need reformatting (call support) | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A11 | No PC or Peripheral Device Connected | Serial cable transfer lost its connection | Reseat or replace the COM cable, reboot PC and machine. On a first-time setup suspect the PC program settings or cable wiring | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A20 | Memory Slot Empty | Information only: the selected slot holds no design | Pick a slot that has a design | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A21 | All Memory Slots are Empty | Information only: nothing is loaded | Load at least one design | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A24 | No More Color Change Codes Found | You reached the last colour change while teaching colours | Normal; finish the needle sequence | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A26 | Sock Frame Origin Not Set | Sock-frame mode needs the second frame origin set after entering Drive | Set the first origin outside Drive, enter Drive, then move the pantograph to the second sock frame origin | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A27 | No more Function Codes Found | Reached the last function code while searching or editing | Normal; no action | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A28 | Calculating Please wait | The Automat is busy | Wait for the message to clear before pressing keys | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A29 | Memory is Full | Every memory location is used | Delete designs before loading more | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A30 | No Disk in Disk Drive | Floppy read requested with no disk | Insert a floppy and retry | VS, VY (floppy models) | Barudan VS/VY error PDF |
| A31 | Disk is Write Protected | The floppy's tab is set to protect | Slide the tab closed; make sure the disk is formatted (FDR for low density, DOS for high density) | VS, VY (floppy models) | Barudan VS/VY error PDF |
| A32 | Error Reading or Writing to Floppy Disk | Bad format, mixed file types or a worn disk | Do not mix .DST and .U01 files on one disk; FDR disks need .U01, .U02 … in order. Try a new disk or a drive cleaner | VS, VY (floppy models) | Barudan VS/VY error PDF |
| A33 | Disk Full | The floppy holds its maximum (36 designs) or is out of space | Delete designs or use another disk | VS, VY (floppy models) | Barudan VS/VY error PDF |
| A34 | Too Many Color Changes in Design | The design has more colour changes than the machine accepts (1,200 on K/X, 400 on V/VT; extras are dropped on V) | Edit the design in software to reduce colour changes | K, X, V series | Barudan KS/KT/XS/XT and VT error PDFs |
| A35 | Spectacle Frame Error | Spectacle Frame mode is on and blocks some movements to protect the machine | If you are not using a spectacle frame, turn the parameter off in MC1 | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A36 | Appliqué Error | Origin key is locked while manual appliqué is on, to protect the presser foot | Turn manual appliqué off before using the origin key | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A37 | USB Memory Device is Full (CF Card is Full on V/VT) | The removable memory has no space | Delete designs from the stick or card | K, X, V series | Barudan KS/KT/XS/XT and VT error PDFs |
| A38 | No USB Memory Device Inserted (No CF Card on V/VT) | Machine cannot see the stick or card | Reseat it, try another stick/card, check the Automat connector for bent pins; on V series check the internal CF card and its board are seated | K, X, V series | Barudan KS/KT/XS/XT and VT error PDFs |
| A39 | USB (or CF) Read/Write Error | The stick or card could not be read or written | Retry, then use another stick or card | K, X, V series | Barudan KS/KT/XS/XT and VT error PDFs |
| A40 | Network Error | The machine dropped off DFS (Design File Server) or LEM network software | Check the cable, close and reopen DFS/LEM, reboot PC and machine. For intermittent drops reroute the cable away from power cables or shorten it | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| A41 | Design Data Reading Error | The file has a format problem or bad header | Re-save the design from your digitizing software or load a known-good file | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D01 | Needle Bar Not Locked | The colour-change lock sensor is not made | Turn the colour-change assembly by hand until the lock sensor engages; check the sensor LED. Do not force a bind (see D05) | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D03 | Color Change Lock Error | Lock sensor not engaged or not working | Same as D01: rotate the colour change into a locked position, check the sensor | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D04 | Color Change Needle Sensor Error | The needle-select board does not see exactly one needle sensor on | Rotate the colour change by hand; if no bind, check the needle-select board for a bent sensor plate or failed sensor and replace the board | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D05 | Color Change Error | The machine failed to complete a colour change | Rotate the colour change by hand to find the bind: stuck thread-keep solenoid, jump solenoid not engaging, broken take-up lever, side cover rubbing, or degree wheel not at stop position. Power off and on after fixing | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D06 | Main Motor Trip Error | The main motor tripped | Restart once. If it repeats, power off and turn the degree wheel by hand to feel for a bind (see D07) | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D07 | Main Motor Overload Error | The main shaft is too hard to turn | Power off, turn the degree wheel by hand, remove the throat plate and clear thread wrapped behind the hook. Oil the machine. Call support if no bind is found | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D08 | Frame Limit Error | The pantograph would pass a soft limit set in the MC parameters | Move the design origin so the trace stays inside the field; call support to change soft limits | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D09 | Start/Stop Switch Error | A start or stop switch is stuck on | On VT, first make sure the blue head toggle on the tension assembly is up. Then check the switches and wiring | K, X, V series | Barudan KS/KT/XS/XT and VT error PDFs |
| D10 | Head Switch Error | The head switch on the tension assembly is off | Turn the head switch on (single heads) | KS, KY, KT single heads | Barudan KS/KT/XS/XT error PDF |
| D11 | Rotary Encoder Error | The main shaft encoder has a fault | Call Barudan tech support | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D12 | Trimmer Slider Error | The trimmer slider is stuck down or caught on untrimmed thread | Break the thread by hand, pull about 50 mm free, and let the slider lift it into the catch. If it keeps happening, adjust the trimmer and replace the blades and wave washer; clean a sticky slider | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D13 | No further Stitch Back or Automending due to 1600 stitch limit | Back-stitch/automend has reached its 1,600-stitch limit | Use Float to move back further | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D14 | Push Start Button | Waiting for the operator | Press Start | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D16 | Bobbin Break | The optional bobbin detector saw the bobbin thread run out or break | Replace or rethread the bobbin | K, X, V series (with bobbin detector) | Barudan KS/KT/XS/XT error PDF |
| D19 | Stopped for Stop Code | The design contains a stop | Normal; continue | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D20 | End of Automending | Automend has finished | Normal; continue | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D21 | Stopped by Stop Switch | Someone pressed Stop | Normal; continue | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D22 | Trimmer Motor Error | The trimmer motor jammed or did not stop in position | Power off to reset. Clear birdnested thread from under the throat plate and reset the trimmer blade adjustment | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D23 | Stopped for Appliqué | Stop code reached with the appliqué program on | Place or trim the appliqué and continue | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D25 | Stopped for Thread Break | A thread break was detected | Rethread and continue. For false stops, check the thread is wrapped round the detect wheel; on tiny stitches raise MC1 parameter #04 (T-Break) | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D26 | Pulse Motor Circuit Overheat | The pantograph drive electronics overheated | Power off to cool, clean lint from the fan and vents, confirm the fan runs. Call support if it returns | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D27 | Stopped for Temporary Repair Stop | A temporary stop was inserted on the last run | Normal; continue | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D28 | No further Stitch Back or Automending due to Color Change | Cannot back up past a colour change | Do a manual trim first | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D29 | Servo Driver Error | The pantograph was jammed or the servo electronics faulted | Power off, push the pantograph by hand to find and clear any bind, power on. Call support if it repeats | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D30 | Head/Duct Board Switch Error | More than two switches on a head/duct board are on, or a ribbon cable is loose | Correct the switch settings and reseat or replace the ribbon cable between head and duct boards | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D31 | Driver Box/Board Communication Error | The Automat cannot see the driver board | Check the cables from the Automat to the driver board, then call support | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D32 | Stopped for Sub End Code | Roll-to-roll mode reached a sub-end code | Normal in roll-to-roll work | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D33 | Power Interrupt Error | Power dipped or dropped | Power off and on. If it repeats, try another outlet or a circuit not shared with other equipment | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D34 | Stopped by Light Curtain | The optional light curtain was broken | Clear the beam path or check the light curtain | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D35 | Lubrication Error / Lubrication Message | Auto-lube device fault, or the lubrication reminder on machines without it | Check the lube device, or oil the machine and reset the reminder | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D36 | Stopped for Bobbin Counter | The bobbin counter reached its set count and trimmed | Change the bobbin and press Start | K, X, V series | Barudan KS/KT/XS/XT error PDF |
| D37 | Sequin Device Error | Sequin driver problem | Make sure the sequin driver box is on; call support | K, X, V series (sequin) | Barudan KS/KT/XS/XT error PDF |
| D38 | Chenille Driver Error | Chenille drive box fault | Reboot and make sure the chenille driver box is on; check the needle-bar rotation motor wiring | Chenille models | Barudan KS/KT/XS/XT error PDF |
| D39 | Looper Motor Error | Looper motor not at its sensor position | Reboot; turn the looper shaft by hand until its top sensor turns on | Chenille models | Barudan KS/KT/XS/XT error PDF |
| D40 | Chenille Thread Clamp Motor Error | Tension release motor not at its sensor | Reboot; turn the tension release shaft by hand until its sensor turns on | Chenille models | Barudan KS/KT/XS/XT error PDF |
| D41 | Chenille Needle Height Error | Needle-bar height or cancel position is wrong | Reboot; with power off, turn the leveling shaft and free any binding levers; check the height origin sensor LED | Chenille models | Barudan KS/KT/XS/XT error PDF |
| D42 | Chenille Error | Other chenille fault, usually the stepper driver board | Call support | Chenille models | Barudan KS/KT/XS/XT error PDF |
| D43 | Presser Foot Set Error | Presser foot setting fault | Call support | KS/KT, XS/XY | Barudan KS/KT/XS/XT error PDF |
| D44 | Lock Stitch Zig-Zag Driver | Zig-zag unit driver fault | Call support | Zig-zag equipped | Barudan KS/KT/XS/XT error PDF |
| D45 | Lock Stitch Zig-Zag Tension | Zig-zag tension fault | Call support | Zig-zag equipped | Barudan KS/KT/XS/XT error PDF |
| D46 | Lock Stitch Zig-Zag Error | Other zig-zag fault | Call support | Zig-zag equipped | Barudan KS/KT/XS/XT error PDF |
| D47 | B-PASS message | Stopped by B-PASS production instructions | Follow the production instruction, then continue | KS/KY/KT with B-PASS | Barudan KS/KT/XS/XT error PDF |
| — | Unexpected Fatal Error | BEAT-900 system fault | Power on while tapping Scroll Lock to reach the shell menu, then run Update System, System Reset | BEAT-900 | Barudan America FAQ |
| — | Call Barudan America (time clock) | The machine's time clock is about to expire or has expired and needs a password | Call the number shown; a technician gives the password | Machines with time clock | Barudan America FAQ |

## Common problems and fixes
### Upper thread keeps breaking or fraying
**Symptoms:** thread, tension, needle
**Likely causes:** threading missed a guide, too much tension, burred needle or presser foot, needle not centred in the foot, dry needle bars, poor thread
1. Rethread the needle from the cone, checking every guide and the clamp pin, and make sure the thread is seated between the tension discs.
2. Fit a new 75/11 needle with the scarf to the back; replace any needle that breaks thread more than once in a run.
3. Loosen the top tension slightly and sew an 18 mm capital "I" test.
4. Look at the presser foot and throat plate for nicks; polish or replace. Make sure the needle is centred in the foot hole.
5. Clean and oil the needle bars.
6. If one needle only: swap cones between needles to see if the fault follows the thread or stays with the position.
7. If all needles: check the bobbin, bobbin case, throat plate, needle centring and the hook.
**Call a technician if:** breaks persist on several needles after the steps above.

### Machine does not stop when the thread breaks (or stops for no reason)
**Symptoms:** sensor, thread
**Likely causes:** dirty or stiff check spring (older machines), thread not wrapped round the rotary detect wheel, upper and lower tensioners out of balance
1. On check-spring machines, clean the spring and post and confirm the spring moves freely; back it off slightly.
2. On wheel machines, make sure the thread wraps fully round the detect wheel; for intermittent faults wrap it twice.
3. Balance the top and bottom tensioners so the wheel turns while sewing.
4. If false D25 stops happen on very short stitches, raise MC1 parameter #04 (T-Break).
**Call a technician if:** several needles fail to detect breaks.

### Birdnest under the fabric
**Symptoms:** birdnest, tension, hoop
**Likely causes:** unbalanced tension, flagging fabric, hook assembly problem
1. Rethread the top thread and run the "I" test to confirm tension.
2. Hoop tighter and check the gap between the hoop and the sewing arm; a large gap lets the fabric flag.
3. Remove the throat plate and clear all thread from the hook area.
4. Check the positioning finger is not too close to the hook basket and the hook turns freely.
**Call a technician if:** nesting continues with good tension and tight hooping.

### Skipped stitches or bobbin not being picked up
**Symptoms:** timing, needle, bobbin
**Likely causes:** bad threading, low or empty bobbin, dry hook or needle bars, bent needle, hook timing (last)
1. Rethread and fit a new needle the right way round.
2. Replace a low bobbin.
3. Oil the hook raceway and needle bars.
4. Only then check hook timing: at 25° on the degree wheel (bridge heads) or 23° (arm/single heads) the hook point should sit just behind the needle scarf, above the eye, with about half to one thread width clearance.
5. Sew 20 mm block letters "H O X" to test every pantograph direction.
**Call a technician if:** you are not comfortable loosening the hook screws; timing usually only shifts after something jams the hook, the needle size changes by more than one size, or thread builds up behind the hook.

### Needle hit the hoop
**Symptoms:** needle, hoop, timing
**Likely causes:** design origin off, hoop too small for the design, wrong frame selected
1. Replace the needle and straighten or replace the presser foot.
2. Check the take-up levers line up at TOP; one low lever means the head is out of sync.
3. Trace the design before sewing.
**Call a technician if:** problems continue; the needle bar driver may be damaged.

### D12 trimmer slider error or threads not trimming
**Symptoms:** trimmer, birdnest
**Likely causes:** untrimmed thread holding the slider down, dull blades, worn wave washer, birdnest knocked the trimmer out
1. Break the thread by hand, pull about 50 mm free and let the slider lift it.
2. Clear thread and lint from under the throat plate.
3. Replace the trimmer blades and wave washer and readjust.
4. Clean the slider so it moves smoothly by hand.
**Call a technician if:** D22 trimmer motor errors keep returning after cleaning.

### Colour change will not complete (D01, D03, D04, D05, N00)
**Symptoms:** colour-change, sensor
**Likely causes:** stuck thread-keep or jump solenoid, broken take-up lever, side cover rubbing, head out of sync, needle-select board fault
1. Power off and turn the colour-change shaft by hand; never force a bind.
2. On VT machines showing "N00", rotate the manual colour-change shaft behind the tension base with a 4 mm Allen key until a needle number shows, then power cycle.
3. Look for a broken take-up lever or a jammed thread-keep part.
4. Check the needle-select board for a bent sensor plate.
**Call a technician if:** all levers are not aligned at TOP or the board needs replacing.

### Main motor trip or overload (D06, D07)
**Symptoms:** motor, oiling
**Likely causes:** thread wrapped behind the hook, dry machine, mechanical bind
1. Power off, remove the drive pulley cover and turn the degree wheel by hand.
2. Remove the throat plate and pick out thread behind the hook.
3. Oil the machine and try again.
**Call a technician if:** the shaft still binds.

### Pantograph errors (D08 frame limit, D29 servo, D26 overheat)
**Symptoms:** frame, motor
**Likely causes:** design outside soft limits, something jamming the frame, blocked cooling fan
1. Re-centre the design so its trace stays inside the field.
2. Power off and move the pantograph by hand to clear any obstruction.
3. Clean lint from the driver fan and vents.
**Call a technician if:** soft limits need changing or D29 returns with nothing jammed.

### Design will not load from USB, CF card or network
**Symptoms:** file, usb, network
**Likely causes:** full memory, damaged stick or card, wrong file type, bad file header, network cable
1. Delete old designs from machine memory (A08, A29).
2. Try a different, freshly formatted USB stick or CF card.
3. Re-save the design from your software as DST or Barudan format and try again (A41).
4. For DFS/LEM network errors, close and reopen the software, reboot both ends, and reroute the cable away from power lines.
**Call a technician if:** no design will load at all; the internal CF card may need reformatting.

### Bobbin thread not centred on the back
**Symptoms:** bobbin, tension
**Likely causes:** positioning finger off-centre, bobbin tension wrong
1. Aim for about one third bobbin across the back of a satin column.
2. If the bobbin is off to one side on every needle, remove the throat plate and shift the positioning finger so it is centred on the needle.
3. If width is wrong on every needle, adjust bobbin tension; if it varies needle to needle, adjust top tension instead.
**Call a technician if:** the finger cannot be centred.

### Cap embroidery problems
**Symptoms:** cap, registration, speed
**Likely causes:** sewing caps too fast, loose cap hooping, wrong frame setting
1. Keep cap speed at or below 1,000 spm (Barudan's own limit on XL2 and LY machines).
2. Hoop the cap tightly in the Advantage EX or Performance cap frame using Barudan's hooping guide.
3. Sew caps from the centre outward and bottom up in your digitizing.
**Call a technician if:** the cap drive slips or the frame does not seat.

## Maintenance schedule
| Interval | Task | Notes |
|---|---|---|
| Every 4–6 hours of sewing | One small drop of clear machine oil in the hook raceway | Barudan's FAQ says every 4–8 hours; use a cotton swab to avoid over-oiling |
| Every bobbin change | Brush lint and thread from the hook and bobbin area | Lint behind the hook causes motor overloads and birdnests |
| Weekly | Oil the drive shaft (about 3 drops) and hook shaft bushing (2 drops) | Colour change to the last needle first on CAII/CBII/CBIII |
| Weekly | Bearing oil (2 drops) in each red hole for crank rod and take-up drive lever; one drop each on needle-bar drive lever and links | Machine stopped while oiling |
| Every two weeks | Oil the needle bar felts through the oil holes | Do not over-oil; wipe excess |
| Every 6 months | White lithium spray grease on take-up levers, take-up cam groove and presser foot cam | Head cover off |
| Yearly | Lithium grease on the colour-change cam | Power off; tension base removed |
| As needed | Change needles when thread breaks start repeating | No fixed schedule |
| Overnight / long idle | Switch off the main breaker | Protects against lightning and surges |

## Settings that cause stitch problems
- **T-Break (MC1 parameter #04):** too low gives false thread-break stops on tiny stitches; raise it a step at a time.
- **Soft limits (MC2 / MC parameters):** set too tight they cause D08 frame-limit stops on designs that would physically fit.
- **Spectacle Frame (MC1):** if left on when no spectacle frame is fitted, the machine refuses some moves and shows A35.
- **Manual appliqué:** blocks the origin key (A36); turn it off when not doing appliqué.
- **Tape code and baud rate (IN COM):** must match the PC software for serial transfers or you get A05.
- **Colour-change limit:** V/VT machines keep only 400 colour changes and drop the rest; K/X machines refuse designs over 1,200.
- **Bobbin counter and lubrication message:** if set, the machine stops by design (D36, D35); this is not a fault.
- **Cap speed:** running caps at flat speed causes flagging and breaks; Barudan rates caps 100–200 spm below flats (for example 1,200 flats / 1,000 caps on the XL2).
- **Three-tensioner balance (9-needle heads):** the lower rotary tensioner is for fine adjustment only; if it is cranked so hard the wheel stops, thread-break detection fails.
- **Presser foot height:** SH heads use a 0.7–0.8 mm gap between foot and throat plate at 0°; a foot set too high lets fabric flag.

## Official manuals, FAQs and support
- [Barudan America support](https://www.barudanamerica.com/support/) — tech support phone numbers, service request form, links to all publications
- [Barudan America FAQ](https://www.barudanamerica.com/faq/) — birdnesting, thread breaks, tension, check spring, oiling, model and serial number lookup
- [KS/KY/KT/XS/XY/XT error messages (PDF)](https://www.barudanamerica.com/wp-content/uploads/2020/06/KS_KY_KT_XS_XY_XT-Error-messages.pdf) — full A and D message list with fixes
- [XS/XY error messages (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/XS-XY_Error_Messages.pdf) — X-series list
- [VS/VY error messages (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/VS-VY_Error_Messages.pdf) — V-series list including floppy messages
- [VT error messages (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/VT_Error_Messages.pdf) — Elite single-head list
- [Model numbering decoder (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/KBModelDecode.pdf) — what each letter in a Barudan model name means
- [Lubrication charts and guides](https://www.barudanamerica.com/lubrication/) — oiling guides by sewing head and model
- [Maintenance documents](https://www.barudanamerica.com/maintenance/) — maintenance manuals, hook timing, needle depth, cap frame mounting
- [Hook timing for ZQ/ZN heads (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/KBHookTiming.pdf) — checking and setting hook timing
- [Elite Pro oiling chart (PDF)](https://www.barudanamerica.com/wp-content/uploads/2018/11/KBIMOilingPro.pdf) — intervals for each oiling point
- [Embroidery advice](https://www.barudanamerica.com/embroidery-advice/) — placement, backing and needle charts, cap hooping
- [Barudan worldwide agency finder](https://barudan.co.jp/en/) — support outside the USA and Canada

## Frequently asked questions
### What does D25 mean on a Barudan?
D25 is "Stopped for Thread Break". Rethread the broken needle and press Start. If the thread is not actually broken, the thread is probably not wrapped round the detect wheel, or the T-Break parameter is too sensitive for very short stitches.

### How do I fix a D12 error on my Barudan?
D12 means the trimmer slider is stuck down or caught on thread. Break the thread by hand, pull about 50 mm loose and let the slider lift it. If it keeps happening, the trimmer blades and wave washer need replacing and the trimmer needs adjusting.

### How often should I oil a Barudan embroidery machine?
Put one small drop of oil in the hook raceway every 4–8 hours of sewing. Weekly points (drive shaft, crank rod, take-up drive) and every-few-months grease points are shown on your model's oiling chart on the Barudan America lubrication page.

### Is my Barudan hook timing off?
Probably not. Barudan says to check threading, the bobbin and oiling first. Timing usually only changes after something jams the hook, you change needle size by more than one size, or thread builds up behind the hook.

### How do I find out what model and year my Barudan is?
The name plate is under the table top on single heads and on the frame near the centre on multi-heads. For US-built machines the first two digits of the serial number are the year, and a final letter A–M (no I) gives the month.

### What file format do Barudan machines read?
Barudan machines read Barudan-format designs (FDR disks use .U01, .U02 … file names; DSB is the other common Barudan format) and also Tajima DST. When sending over a serial cable, the PC and machine must use the same tape code (U for Barudan, EL for Tajima).

### Why does my Barudan say to call Barudan America?
The machine has a time clock that locks it once it expires. Call the number on the screen and a technician will give you the password to enter.

## Diagrams

- [Five-minute diagnosis](https://easydigitizer.com/troubleshooter/img/diagnose-flow.svg): Where to start when the machine stops or sews badly.
- [Upper thread path](https://easydigitizer.com/troubleshooter/img/thread-path.svg): Every guide from the cone to the needle eye — the fix for most breaks and nests.
- [Why birdnests happen](https://easydigitizer.com/troubleshooter/img/birdnest.svg): What a nest is, the usual causes in order, and how to clear one safely.
- [The I-test for tension](https://easydigitizer.com/troubleshooter/img/tension-test.svg): Read the back of a satin column to balance top and bobbin tension.
- [Bobbin drop test](https://easydigitizer.com/troubleshooter/img/bobbin-drop-test.svg): Set bobbin tension before you touch the top tension.
- [Needle orientation](https://easydigitizer.com/troubleshooter/img/needle-orientation.svg): Long groove to the front, scarf to the hook, pushed fully up.
- [Hook timing](https://easydigitizer.com/troubleshooter/img/hook-timing.svg): What correct hook-to-needle timing and clearance look like.
- [Presser foot height](https://easydigitizer.com/troubleshooter/img/presser-foot-height.svg): Too high causes flagging and loops; too low drags and breaks thread.
- [Hooping layers](https://easydigitizer.com/troubleshooter/img/hooping.svg): Firm, flat and square — the root of most puckering and registration faults.
- [Caps: frame and sequence](https://easydigitizer.com/troubleshooter/img/cap-frame.svg): Cap frame set-up, centre-out sewing and safe sew height.
- [Cleaning and oiling points](https://easydigitizer.com/troubleshooter/img/maintenance-points.svg): Daily and weekly care points on a multi-needle head.

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Part of the EasyDigitizer embroidery machine troubleshooter: https://easydigitizer.com/troubleshooter/ · Agent playbook: https://easydigitizer.com/troubleshooter/agent.md · Not affiliated with any machine maker; the machine's own manual takes priority. Design-related sew-out problems (density, underlay, pull compensation): https://easydigitizer.com/help